Sheath to protect an aerosol valve stem

ABSTRACT

An aerosol dispenser having a valve for dispensing product through a valve stem. The valve stem is protected by a sheath, to reduce breakage. The sheath extends equal to or above the height of the valve stem, to absorb axially compressive loads and side impact loads. The sheath can occur in the aerosol dispenser, an aerosol container, an outer container, a preform and/or in the valve. The aerosol dispenser can include bags, pistons and dip tubes.

FIELD OF THE INVENTION

The present invention relates to aerosol dispensers having a sheath-protected valve stem and components for the manufacture thereof.

BACKGROUND OF THE INVENTION

Aerosol dispensers are well known in the art. Aerosol dispensers typically comprise an outer container which acts as a frame for the remaining components and as a pressure vessel for propellant and product contained therein. Outer containers made of metal are well known in the art. However, metal containers can be undesirable due to high cost and limited recyclability. Attempts to use plastic have occurred in the art. Relevant attempts in the art to employ plastic in aerosol dispensers are found in U.S. Pat. Nos. 2,863,699; 3,333,743; 4,969,577; 8,752,731; 9,296,550; 9,334,103 and 2009/0014679.

The outer containers are typically, but not necessarily, cylindrical. The outer container may comprise a bottom for resting on horizontal surfaces such as shelves, countertops, tables etc. The bottom of the outer container may comprise a re-entrant portion as shown in U.S. Pat. No. 3,403,804 or a base cup as shown in commonly assigned U.S. Pat. No. 8,439,223 and U.S. Pat. No. 9,061,795. Sidewalls defining the shape of the outer container extend upwardly from the bottom to an open top.

The open top defines a neck for receiving additional components of the aerosol dispenser. The industry has generally settled upon a nominal neck diameter of 2.54 cm, for standardization of components among various manufacturers, although smaller diameters, such as 20 mm, are also used. Various neck shapes are shown in U.S. Pat. Nos. 6,019,252; 7,028,866; 7,279,207 and 7,303,087.

Typically a valve cup is inserted into the neck. The valve cup is sealed against the neck to prevent the escape of the propellant and loss of pressurization, such as described in U.S. Pat. Nos. 8,074,847; 8,096,327; 8,844,765; 8,869,842 and 9,505,509. The valve cup holds the valve components which are movable in relationship to the balance of the aerosol dispenser. Suitable valves are shown in commonly assigned U.S. Pat. No. 8,511,522 and U.S. Pat. No. 9,132,955. When the valves are opened, product may be dispensed through a nozzle, etc. as described in commonly assigned U.S. Pat. No. 9,174,229.

A valve may be inserted into the valve cup for selective actuation by the user. The valve is typically normally closed, and may be opened to create a flow path for the product to ambient or a target surface. The valve may be compatible with local recycling standards. Suitable valves are disclosed in commonly assigned U.S. Pat. No. 8,511,522 and U.S. Pat. No. 9,132,955.

If a valve is to be assembled into an aerosol, typically the valve cup is crimped onto the neck of the aerosol container. But this operation is expensive and is difficult to perform with a plastic valve cup. A separate interlock may be used to attach a valve to a valve cup, particularly a plastic valve 28 and plastic valve cup are used. Suitable interlocks include bayonet fittings and threads as disclosed in commonly assigned P&G Case 14458, Ser. No. 15/235,237, filed Aug. 12, 2016. A pressure vessel with a threaded bore is proposed in U.S. Pat. No. 8,505,762.

A bag may be used to contain product for selective dispensing by a user. Dispensing of product from the bag occurs in response to the user actuating the valve. The bag separates product within the bag from propellant disposed between the bag and container. This bag limits or even prevents intermixing of the contents of the bag and the components outside of the bag. Thus, product may be contained in the bag. Propellant may be disposed between the outside of the bag and the inside of the outer container. Upon actuation of the valve, a flow path out of the bag is created. This embodiment is commonly called a bag in can and may be used, for example, in dispensing shaving cream gels. Alternatively, a bag may be directly joined to the valve housing, in a configuration commonly called a bag on valve. A suitable bag configuration is disclosed in commonly assigned P&G Case 14458, Ser. No. 15/235,227, filed Aug. 12, 2016 which teaches attaching a bag to a valve cup.

If a bag configuration is desired, propellant may be disposed between the bag and outer container, as disclosed in U.S. Pat. No. 5,219,005 and in commonly assigned U.S. Pat. No. 8,631,632 and U.S. Pat. No. 8,869,842. Afterwards, product fill may occur in a separate, remote, operation, optionally carried out in another location, which may be in the same country or in a different country as disclosed in commonly assigned 2012/0291911. Such a manufacturing process can conserve costs in production, shipment and/or storage.

An aerosol container having a bag therein may be made from a dual layer preform, having plural layers disposed one inside the other. Relevant attempts include U.S. Pat. Nos. 3,450,254; 4,330,066; 6,254,820; RE 30093 E; WO 9108099 and US 2011/0248035 A1. But each of these attempts requires a separate operation to attach the bag to the relevant component. Each attachment step takes time in manufacturing and creates the opportunity for leakage if not correctly performed. Improvements in dual layer preforms are found in commonly assigned P&G Case 14461, application Ser. No. 15/235,279, filed Aug. 12, 2016.

Alternatively, a dip tube may be used if intermixing of the product and propellant is desired. When the user actuates the valve, the product and propellant are dispensed together through the dip tube. This embodiment may utilize a dip tube. The dip tube takes the product and propellant mixture from the bottom of the outer container. Or a piston may be used to expel product, particularly if highly viscous, as described in 2002/0027146, U.S. Pat. No. 6,375,045 and commonly assigned 2016/0368700.

Collectively, bags, dip tube, pistons and the associated hardware are referred to as product delivery devices. Various formats for the delivery devices may be required for different products, often complicating production. For example, one product may require a dip tube product delivery device in conjunction with a very small nozzle. The next aerosol dispenser on the production schedule may simply require changeout to a new, larger, nozzle.

But if one wishes to then manufacture an aerosol dispenser utilizing a bag for a particular production cycle, then manufacture an aerosol dispenser having a dip tube, for subsequent production cycles, considerable changeout is required. Different outer containers are typically needed to accommodate the different product delivery devices. Likewise, different valves are likely required. As different valves are required, the different outer containers must be matched to accommodate the different valves. Different valves may also require different valve cups which can be plastic and welded into place, be metal and crimped into place or no valve cup at all may be needed. A combination of outer container, valve, product delivery device and associated hardware, if any, is referred to as a format for a particular aerosol dispenser.

But each valve has a valve stem projecting upwardly from the valve body. The valve stem is part of the flow path to ambient and may connect to an actuator used to dispense product from the aerosol dispenser upon demand The valve stem is preferably plastic and prone to breakage during transport and handling, as for example, occurs during shipping in ordinary bins from the site of valve manufacture to valve assembly. The valve stem is further prone to breakage post-assembly, during common soldier stacking of the aerosol containers. If the valve stem breaks, it and the related component parts are subject to scrap, causing downtime and waste. Accordingly this invention, is directed to the problem of mitigating valve stem breakage during aerosol dispenser manufacturing.

SUMMARY OF THE INVENTION

In one embodiment the invention comprises an aerosol dispenser, in another embodiment an aerosol container for an aerosol dispenser, in another embodiment an outer container for an aerosol dispenser, in another embodiment a valve for an aerosol dispenser, in another embodiment a preform for an aerosol dispenser. All of the embodiments have an upwardly projecting sheath. The sheath extends to or beyond a valve stem, protecting the valve stem. The sheath may or may not circumscribe the valve stem.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings are to scale, unless otherwise noted as schematic.

FIG. 1 is a vertical sectional view of an aerosol dispenser according to the prior art and having an exposed valve stem.

FIG. 2 is a side elevational view of an aerosol dispenser according to the present invention, showing the sheath being shown partially in cutaway, an actuator and spray being schematically dispensed from a nozzle, the actuator and nozzle being omitted from all subsequent figures.

FIG. 3 is a vertical sectional view taken along lines 3 - 3 of FIG. 2, showing an aerosol container and having the actuator removed for clarity.

FIG. 4A is a top plan view of a preform suitable for use with the present invention and having a valve thereon.

FIG. 4B is a side elevational view of the valve and preform of FIG. 4A.

FIG. 4C is a bottom plan view of the valve and preform of FIG. 4A.

FIG. 5 is a fragmentary vertical sectional view of an alternative embodiment of a valve and preform, showing the moving assembly in the closed position and the valve having an annular projection which intercepts the inside edge of a sealing surface in the preform and schematically showing the preform as an outer container in phantom.

FIG. 6A1 is a fragmentary vertical sectional view of a preform, having a bag for the product delivery device and having an upstanding annular projection on the bag and downwardly extending projection on the valve, the moving assembly and valve stem of the valve being removed for clarity, and schematically showing external blades on the valve.

FIG. 6A2 is a fragmentary vertical sectional view of a preform, having a bag for the product delivery device and having a downwardly extending annular projections on the valve intercepting the bag and outer container the moving assembly and valve stem of the valve being removed for clarity, and schematically showing external blades on the valve.

FIG. 6B1 is a fragmentary vertical sectional view of an aerosol container, having a bag for the product delivery device, showing the elevated valve stem prior to welding and having internal blades on valve and schematic external blades on the outer container.

FIG. 6B2 fragmentary vertical sectional view of the aerosol container of FIG. 6B1, showing the valve stem coincident the elevation of the sheath post-welding.

FIG. 7A1 is a vertical sectional view of the preform and valve of FIG. 6A having a bag for the product delivery device welded to the preform and showing the valve in the closed position.

FIG. 7A2 is an enlarged fragmentary view of the valve and preform of FIG. 7A1.

FIG. 7B1 is a vertical sectional view of the preform and valve of FIG. 7A1 prior to welding with the energy concentrators in position, the bag energy concentrator depending lower than the outer container energy concentrator and showing the valve in the open position.

FIG. 7B2 is an enlarged fragmentary view of the valve and preform of FIG. 7B1.

FIG. 7C1 is a vertical sectional view of an alternative embodiment of the preform and valve of FIG. 6A having a dip tube for the product delivery device with the energy concentrators in position, the dip tube concentrator depending lower than the outer container energy concentrator.

FIG. 7C2 is an enlarged fragmentary view of the valve and preform of FIG. 7C1, showing the valve and dip tube welded into position.

FIG. 8A is a top perspective view of a valve usable with the present invention.

FIG. 8B is a side perspective view of the valve of FIG. 8A.

FIG. 8C is a bottom perspective view of the valve of FIG. 8A.

FIG. 9 is a schematic fragmentary sectional view of an alternative embodiment of an aerosol container, having the valve threadedly joined to the neck of the outer container and having the sheath projecting upwards from the outer container.

FIG. 10 is a side elevational view of a preform shown partially in cutaway and suitable for use with the aerosol container of FIG. 9.

FIG. 11 is a schematic perspective view of an alternative embodiment of a valve having discrete upstanding struts for the sheath, the struts also functioning as blades, the valve stem omitted for clarity.

FIG. 12 is a schematic side elevational view of an alternative embodiment of a preform having discrete upstanding struts for the sheath, the struts also functioning as blades.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIG. 1, an aerosol dispenser 20 according to the prior art is shown. The aerosol container 22 has an exposed valve stem 28S. The exposed valve step 28S projects above the neck 24 of the outer container 22.

Such a geometry exposes the valve stem 28S to breakage from top loads, as occurs during soldier stacking and from side impact, as occurs during routine handling.

Referring to FIGS. 2 and 3, an aerosol dispenser 20 and aerosol container 22, each having a longitudinal axis is shown. The aerosol dispenser 20 comprises a pressurizeable outer container 22 usable for such an aerosol dispenser 20. The outer container 22 has a neck 24 into which a valve cup 26 is sealingly disposed. A valve 28 and actuator 29 may be disposed in the valve cup 26 for selective dispensing of product 42 from the aerosol dispenser 20. A seal 30 having a surface for sealing a valve 28 to the valve cup 26 may be disposed below the valve cup 26 and valve 28 to prevent escape of product 42 to ambient. As used herein, an aerosol container 20C may be a subset of an aerosol dispenser 20, and have an outer container 22, valve cup 26 sealed thereto with a bag 55/dip tube 56, collectively referred to as a product delivery device 55, 56, joined to the valve cup 26, and optionally propellant 40, but not necessarily a valve 28, actuator 29, labeling, etc. Optionally the valve 28 may be directly joined to the outer container without a separate valve cup 26.

As used herein, the top of the aerosol dispenser 20 or the outer container 22 is taken as the uppermost part, when the aerosol dispenser 20 or container 22 is vertically oriented in its normal use or storage position. As used herein, the bottom of the aerosol dispenser 20 or the outer container 22 is taken as the lowermost part, when the aerosol dispenser 20 or the container 22 is vertically oriented in its normal use or storage position. The top and bottom are longitudinally opposed, with the top typically being open at a neck 24 and bottom typically being a closed end. The terms ‘above’ and ‘below’ refer to relative positions towards and away from the top, respectively. Likewise the terms ‘above’ and ‘below’ refer to relative positions away from and towards the bottom, respectively.

The aerosol dispenser 20 and outer container 22 have a longitudinal axis, defining the main axis. The aerosol dispenser 20 and outer container 22 may be longitudinally elongate, i.e. having an aspect ratio of longitudinal dimension to transverse dimension[s] such as diameter greater than 1, an aspect ratio equal to 1 as in a sphere or shorter cylinder, or an aspect ratio less than 1.

The outer container 22 may comprise metal or preferably plastic, as are known in the art. The plastic may be polymeric, and particularly comprise polyethylene terephthalate (PET) or polypropylene (PP) for all of the components described herein. The outer container 22 may be injection molded or further blow molded in an ISBM process, as well known in the art. The outer container 22 defines a longitudinal axis and may have an opening at one end thereof. The opening is typically at the top of the pressurizeable container when the pressurizeable container is in its-in use position.

The opening defines a neck 24, to which other components may be sealingly joined. The neck 24 has a neck diameter, taken as the inside diameter at the top of the outer container 22.

As the top of the outer container 22 is approached, the outer container 22 may have a neck 24. The neck 24 may be connected to the container sidewall by a shoulder 23. The shoulder 23 may more particularly be joined to the sidewall by a radius. The shoulder 23 may have an annular flat. The neck 24 may have a greater thickness at the top of the outer container 22 than at lower portions of the neck 24 to provide a differential thickness. Such differential thickness may be accomplished through having an internally stepped neck 24 thickness.

A normally closed valve 28 may be disposed in the neck 24. The valve 28 is openable upon demand by a user, in response to manual operation of an actuator 29. The actuator 29 may be depressable, operable as a trigger, etc. to spray product 42 from the aerosol dispenser 20. Illustrative and non-limiting products 42 include shave cream, shave foam, body sprays, body washes, perfumes, cleansers, air treatments, astringents, foods, paint, insecticides, etc.

An optional valve cup 26 may be sealed to the opening of the outer container 22. The valve cup 26 may be sealed to the neck 24 of the outer container 22 using class 1 TPE material. Polyester based TPE sold by Kraiburg TPE GmbH & Co KG of Waldkraiburg, Germany under the name HTC8791-52 and sold by DuPont of Delaware under the name HYTEL may be used for good resistance to Silicone and adhesion to PET. Such a TPE material is believed to fall under Resin Identification Code 1/01 for PETE/PET, as set forth above by the Society of Plastics Industry and ASTM D7611. Or a Styrenic bloc copolymer based TPE such as Kraiburg HTC8791-24 or Krayton elastomer may be used, providing easier process and lower density. Other seal materials include silicone, rubber and similar conformable materials.

If desired, the valve cup 26 may be sealed to the outer container 22 utilizing a press fit, interference fit, solvent welding, laser welding, sonic welding, ultrasonic welding, spin welding, adhesive or any combination thereof. An intermediate component, such as a sleeve or connector may optionally be disposed intermediate the valve cup 26 and neck 24 or top of the outer container 22. Any such arrangement is suitable, so long as a seal adequate to maintain the pressure results.

Referring to FIGS. 4A, 4B and 4C, a preform 60 can be made in a single injection molding operation, providing tolerances suitable for mass production. A first preform 60 is then blow molded in known fashion to make the outer container 22. A valve attachment 25, such as threads, is above the blow molding operation, preventing undue dimensional distortion thereof. A second preform 60 can be used to make the valve cup 26 as the finish and internal bag 55 as the body upon blow molding thereof. One of skill will understand the blow molding step may also include stretching as is known in the art.

The invention further comprises a sheath 28P. The sheath 28P protects the valve stem 28S, as described herein. If the valve stem 28S is broken, or its movement (usually in the axial direction) hindered, scrap ensues. The sheath 28P has a sheath diameter, taken as the internal diameter of the proximal end of the sheath 28P. The sheath 28P has a sheath distal end, taken as the uppermost portion of the sheath 28P without an actuator 29 or other attachment. The distal end of the sheath 28P extends to a position at or above the distal end of the valve stem 28S.

Furthermore, the sheath 28P may have internal or external blades 28B. The blades 28B may assist in theadedly assembling the valve 28 to the outer container 22, or in spin welding the valve 28 to the outer container 22. The blades 28B can intercept an external drive, then transmit torque to the sheath 28P about the longitudinal axis, causing responsive rotation of the sheath 28P as desired. Particularly, each blade 28P may have a face to engage the external drive.

Preferably a plurality of two or more blades 28P is used, to distribute torsional loading. The sheath 28P has an inner periphery and an outer periphery. The blades 28 may extend radially outwardly from the outer periphery, providing the benefit of greater torque. Alternatively, blades 28 may extend radially inwardly from the inner periphery, providing the benefit of conserving space.

Optionally, the bag 55 can be integral with the valve cup 26. By integral it is meant that the bag 55 and valve cup 26 are monolithic, molded at the same time or molded of two different materials melted together in a permanent manner An integral bag 55 and valve cup 26 cannot be separated into two components without tearing or undue deformation. A container 22 made from a preform 60 using ISBM is referred to herein as a molded container 22.

Referring to FIG. 5, a valve 28, in turn, may be disposed within the valve cup 26. The valve 28 provides for retention of product 42 within the aerosol dispenser 20 until the product 42 is selectively dispensed by a user. The valve 28 may be selectively actuated by an actuator 29. A nozzle 27 and related valve 28 components may optionally be included, depending upon the desired dispensing and spray characteristics. The valve 28 may be attached using conventional and known means. The valve 28 and actuator 29 may be conventional and do not form part of the claimed invention. Selective actuation of the valve 28 allows the user to dispense a desired quantity of the product 42 on demand

The valve 28 may provide for dispensing from the top of the bag 55/dip tube 56 through one or more ports and into the valve stem. Optionally, the valve 28 may have a bypass outside the ports to accommodate relatively viscous product 42.

The valve 28 comprises a moving assembly 28M disposed within a housing 28H. The housing 28H may be relatively rigid, while the moving assembly 28M is resiliently returnable to a closed position once dispensing is complete. The housing 28H has a lateral component which serves for attachment to the preform 60/outer container 22.

The valve 28 may be a normally closed valve 28. A normally closed valve 28 is closed in its rest position. The valve 28 is only opened when actuated upon demand by a user.

A valve stem 28S provides a product 42 flow path and joins the actuator 29 to the valve 28 in fluid communication. The valve stem 28S may be disposed within and cause responsive movement in the moving assembly 28M. The valve stem 28S has a valve stem distal end, taken as the uppermost portion of the valve stem 28S without an actuator 29 or other attachment.

Referring to FIGS. 6A1 and 6A2, the housing 28H of valve 28 may have an upwardly projecting sheath 28P. The upstanding sheath 28P may circumscribe and extend longitudinally beyond the valve stem 28S. By extend longitudinally beyond, it is meant that the distal end of the sheath 28P is disposed above the distal end of the valve stem 28S when the valve stem 28S is in the normally closed position. The projections shown in FIGS. 6A1 and 6A2 may assist in optional, welding, particularly spin welding, if used to join various components.

The sheath 28P has optional external blades 28B to assist in spin welding or other joining operations. It is to be understood the optional external blades 28B may be disposed on the valve 28 as shown or on the preform 60/neck 24. Likewise, the optional internal blades 28B may be disposed on the valve 28 as shown or on the preform 60/neck 24.

Referring to FIGS. 6B1 and 6B2, the assembly may have both internal blades 28B and external blades 28B. This arrangement provides the benefit that two coaxial external drives may be used. The external drives may be used for counter-rotation, or one may hold a set of blades 28B stationary while the other blades 28B respond to torsionally applied rotational forces. FIG. 6B1 shows the valve stem 28S projecting above the height of the sheath 28P prior to welding a vertical distance ‘H’. FIG. 6B2 shows that, as a result of the welding operation, the valve stem 28S has dropped to an elevation coincident with and protected by the sheath 28P.

Referring back to FIGS. 1-2, the product delivery device 55, 56 may be used to contain and/or provide for delivery of product 42 from the aerosol dispenser 20 upon demand. Suitable product delivery devices 55, 56 comprise pistons, bags 55, dip tubes 56, and do not form part of the claimed invention, except as specifically claimed herein. If desired, the product delivery device 55, 56 may further comprise a metering device for dispensing pre-determined, metered quantities of product 42, as described in U.S. Pat. Nos. 2,815,889; 4,142,652 and 5,421,492. The product delivery device 55, 56 may also comprise an inverting valve having a ball therein to alter product 42 flowpath.

If desired the product delivery device 55, 56 may comprise a dip tube 56 disposed in a bag 55. Such a dip tube 56 may reach to nearly the bottom of the bag 55, or be juxtaposed near the middle of the bag 55. A dip tube may be made according to U.S. Pat. No. 8,091,741.

The pressurizeable container may further include a propellant 40. The propellant 40 may comprise hydrocarbons, nitrogen, air and mixtures thereof. Propellant 40 listed in the US Federal Register 49 CFR 1.73.115, Class 2, Division 2.2 are also considered acceptable. The propellant 40 may particularly comprise a Trans-1,3,3,3-tetrafluoroprop-1-ene, and optionally a CAS number 1645-83-6 gas. One such propellant 40 is commercially available from Honeywell International of Morristown, New Jersey under the trade name HFO-1234ze or SOLSTICE.

If desired, the propellant 40 may be condensable. Generally, the highest pressure occurs after the aerosol dispenser 20 is charged with product 42 but before the first dispensing of that product 42 by the user. A condensable propellant 40, when condensed, provides the benefit of a flatter depressurization curve at the vapor pressure, as product 42 is depleted during usage. A condensable propellant 40 also provides the benefit that a greater volume of gas may be placed into the container at a given pressure. A condensable propellant 40, such as HFO-1234ze, may be charged to a gage pressure of 100-400 kPa at 21 degrees C.

If desired, the outer container 22, valve cup 26, valve 28, and/or piston may be polymeric. By polymeric it is meant that the component is formed of a material which is plastic, comprises polymers, and/or particularly polyolefin, polyester or nylons, and more particularly PET. Thus, the entire aerosol dispenser 20 or, specific components thereof, may be free of metal, allowing microwaving. Microwave heating of the aerosol dispenser 20 or pressurizable container therefor provides for heating of the product 42 prior to dispensing. Heating of the product 42 prior to dispensing may be desirable if the product 42 is applied to the skin, becomes more efficacious at lower viscosities, or is to be eaten.

The valve cup 26 may have a valve cup 26 periphery complementary to the neck 24 periphery. At least one of the valve cup 26 and/or container neck 24 may have one or more channels therethrough. Additionally or alternatively, the channels may be formed at the interface between the valve cup 26 and container neck 24. The channels may be formed by irregularities, such as crenulations, merlins, serrations, notches, teeth, etc. between valve cup 26 and/or container neck 24.

The outer container 22, and all other components, optionally excepting the TPE seal, may comprise, consist essentially of or consist of PET, PEN, Nylon, EVOH or blends thereof to meet DOT SP 14223. All such materials may be selected from a single class of recyclable materials, as set forth above by the Society of Plastics Industry and ASTM D7611. Particularly all components of the aerosol dispenser 20 may comprise the aforementioned TPE and PET/PETE, Resin Identification Code 1/01. This material selection provides the benefit that the entire aerosol dispenser may advantageously be recycled in a single stream.

Alternatively, the valve cup 26 and/or bag 55 may comprise plural layers such as nylon with EVOH, PET and/or polyolefin materials. Three layers may be utilized, such as PET/Nylon/PET or PET/EVOH/PET. The layers may be co-molded or overmolded. The multi-layer arrangements may provide increased barrier resistance and reduced failure rates.

The outer container 22, and/ optionally the product delivery device 55, 56, may be transparent or substantially transparent. This arrangement provides the benefit that the consumer knows when product 42 is nearing depletion and allows improved communication of product 42 attributes, such as color, viscosity, etc. Also, labeling or other decoration of the container may be more apparent if the background to which such decoration is applied is clear.

Suitable decoration includes labels 57. Labels 57 may be shrink wrapped, printed, etc., as are known in the art.

The outer container 22 may define a longitudinal axis of the aerosol dispenser 20. The outer container 22 may be axisymmetric as shown, or, may be eccentric. While a round cross-section is shown, the invention is not so limited. The cross-section may be square, elliptical, irregular, etc. Furthermore, the cross section may be generally constant as shown, or may be variable. If a variable cross-section is selected, the outer container 22 may be barrel shaped, hourglass shaped, or monotonically tapered.

The outer container 22 may range from 6 to 60 cm, and particularly 10 to 40 cm in height, taken in the axial direction and from 3 to 60 cm, and particularly 4 to 10 cm in diameter if a round footprint is selected. The outer container 22 may have a volume ranging from 40 to 1000 cc exclusive of any components therein, such as a product delivery device 55, 56. The outer container 22 may be injection stretch blow molded. If so, the injection stretch blow molding process may provide an overall stretch ratio of greater than 8, 8.5, 9, 9.5, 10, 12, 15 or 20 and less than 50, 40 or 30.

The outer container 22 may sit on a base. The base is disposed on the bottom of the outer container 22. Suitable bases include petaloid bases, champagne bases, hemispherical or other convex bases used in conjunction with a base cup. Or the outer container 22 may have a generally flat base with an optional punt.

A manifold may supply propellant 40, under pressure, through at least one channel between the valve cup 26 and container neck 24. The manifold may be retractingly disposed above the container 22. The manifold may be brought into contact with the valve cup 26, forming a temporary seal therebetween. Suitable channels are particularly described in commonly assigned U.S. Pat. No. 8,869,842 to Smith at FIG. 8, column 7, lines 57 to column 8, line 2 and column 8, lines 44-60. While the temporary seal is established between the manifold and valve cup 26, the propellant 40 may be charged into the outer container 22.

The aerosol dispenser 20, as presented to a user may have an initial pressure. The initial pressure is the highest pressure encountered for a particular filling operation, and corresponds to no product 42 yet being dispensed from the product delivery device 55, 56. As product 42 is depleted, the outer container 22 approaches a final pressure. The final pressure corresponds to depletion of substantially all product 42, except for small residual, from the product delivery device 55, 56. One benefit of the invention is that the residual product 42, remaining at end of life, is unexpectedly minimized

This arrangement provides the benefit that propellant 40 may be charged to a lesser pressure than the desired starting pressure, decreasing propellant 40 charge time and reducing pressure applied to the charging machinery. Another benefit is that propellant 40 is disposed as needed for the end use when the aerosol dispenser 20 is ready for sale, product 42 fill and upon product 42 depletion may be recharged with product 42 and reused.

At 21 degrees C., the outer container 22 may be pressurized to an internal gage pressure of 100 to 1300, 110 to 490 or 270 to 420 kPa. A particular aerosol dispenser 20 may have an initial propellant 40 pressure of 1100 kPA and a final propellant 40 pressure of 120 kPa, an initial propellant 40 pressure of 900 kPA and a final propellant 40 pressure of 300 kPa, an initial propellant 40 pressure of 500 kPA and a final propellant 40 pressure of 0 kPa, and any values therebetween.

Referring to FIGS. 7A1, 7A2, 7B1, 7B2, 7C1 and 7C2, a permanent seal between components of the aerosol dispenser 20 is desired, the seal may be welded. Particularly, if the components have compatible melt indices, such components may be sealed by welding to retain propellant therein. Suitable welding processes may include sonic, ultrasonic, spin, and laser welding. Welding may be accomplished with a commercially available welder, such as available from Branson Ultrasonics Corp. of Danbury, Conn. Alternatively or additionally, the channel may prophetically be blocked by a plug or sealed by adhesive bonding. Suitable sealing processes for the channel are particularly described in commonly assigned U.S. Pat. No. 8,869,842 to Smith at FIG. 9 and column 8, lines 30-43.

Spin welding has been found to be particularly preferred. Spin welding provides the benefit that the energy plane is generally confined to a small vertical space, limiting unintended damage of other components not intended to be welded or receive such energy. Spin welding further provides the benefit that both the outer container weld 22W and the weld 55W for the bag 55/the weld 56W for the dip tube 56 may occur simultaneously or nearly at the same time, increasing product speed.

Or if desired, the product delivery device weld 55W, 56W may occur first, providing a pressure boundary between the product delivery device 55, 56 and the valve 28. During establishment of or once the pressure boundary has been established, the propellant 40 charge may occur, allowing for simultaneous welding and charging. After the product delivery device weld 55W, 56W and propellant 40 charge occur the outer container weld 22W may be completed, providing for containment of the propellant 40 within the outer container 22.

The timing of the product delivery device weld 55W, 56W occurring after, or preferably before the outer container weld 22W may be influenced by respective projections 22E, 55E, 56E. Particularly the valve 28 may have a depending product delivery device projection 55E, 56E, circumscribing an outer container projection 22E. The if the projections equally contact the respective mating surfaces, the product delivery device weld 55W, 56W, and outer container weld 22W will generally simultaneously occur. Preferably, the product delivery device projection 55E for the bag 55/56E for the dip tube 56 depends further than the outer container projection 22E, so that welding order allows for propellant charge 40 as described herein.

If the product delivery device 55, 56 is a dip tube 56, the propellant 40 charge and product 42 charge may simultaneously occur. The propellant 40 and product 42 may be premixed into a single charge, which occurs during the welding operation. Alternatively either a bag 55 or a dip tube 56 aerosol dispenser 20 may have the product 42 later added through the valve 28, as is known in the art.

The valve 28 is welded to the outer container 22 in fluid tight relationship by an outer container weld 22W. The outer container weld 22W occurs between the valve 28 and the first annular sealing surface. Likewise, a product delivery device 55, 56 is welded to the valve 28 or the outer container 22 in fluid tight relationship by a product delivery device weld 55W, 56W. The product delivery device 55, 56 weld occurs between the product delivery device 55, 56 and the second annular sealing surface. The product delivery device weld 55W, 56W is radially spaced apart from the outer container weld 22W.

If desired, the valve 28 may be welded to the second sealing surface directly or may be welded to the product delivery 55, 56. This assembly geometry provides the flexibility for various geometries depending upon the specific aerosol dispenser and product 42 combination desired.

The outer container 20C according to the present invention has two welds a product delivery device weld 55W, 56W and an outer container weld 22W, which are mutually radially spaced apart from the other. If one or more of the product delivery device weld 55W, 56W and outer container weld 22W are relatively thick in the radial dimension, and spaced relatively close to the other, the product delivery device weld 55W, 56W and outer container weld 22W may appear to merge. Such an embodiment is contemplated and within the scope of the present invention. While two radially spaced apart welds 55W, 56W, 22W are shown, one of skill will recognize that any plurality of welds may be utilized. Additional welds may be used to join additional components as desired or to reinforce the product delivery device weld 55W, 56W and outer container weld 22W.

The outer container weld 22W may circumscribe the product delivery device weld 55, 56W in concentric or eccentric fashion. The outer container weld 22W and product delivery device weld 55, 56W may be of equal or unequal radial thickness, require equal or unequal energy to effect a proper bond and may be equally or unequally spaced from the other and equally or unequally spaced about the longitudinal axis.

If desired, the outer container 22 and propellant 40 may be assembled at a first location. The product 42, decoration, etc. may be added at a second location, as described in commonly assigned 2012/0292338 and 2012/0291911.

Thus, the aerosol dispenser 20 may be made by providing nested preforms 60 comprising an outer preform 60 and inner preform 60 disposed therein. The inner preform 60 has a valve cup 26 at the open end thereof.

The preforms 60 are blowmolded together to form an outer container 22 and having an open end and an inner bag 55 depending therefrom towards the closed end of the outer container. Propellant 40 is charged between the bag 55 and outer container 22. The valve cup 26 is sealing joined to the open end of the outer container 22 to contain the propellant 40 therein and form an aerosol container 20C. The aerosol container 20C may then be stored as needed or directly shipped for product 42 fill, installing the valve 28, actuator 29, label, etc.

Alternatively, an integral inner bag 55/valve cup 26 combination may be provided and inserted into an outer container 22. The inner bag 55 is inserted in the open end of the outer container 22. Propellant 40 is charged between the bag 55 and outer container 22. The integral valve cup 26 is sealingly joined to the open end of the outer container 22 to contain the propellant 40 therein and form an aerosol container 20C. The aerosol container 20C may then be stored as needed or directly shipped for product 42 fill, installing the valve 28, actuator 29, label, etc. In either alternative, the inner preform 60 may have a neck 24 according to the present invention, with the first annular sealing surface 31 and second annular sealing surface 32 as described and claimed herein.

While a round outer container 22 is described, the invention is not so limited. The outer container 22, and thus the valve attachment, first annular sealing surface 31 and second annular sealing surface 32 may be of any desired shape so long as the circumference of the second annular sealing surface 32 is less than and interior to the circumference of the first annular sealing surface 31 which in turn is less than and interior to the circumference of the valve attachment circumference. Preferably the valve attachment circumference, first annular sealing surface 31 circumference and second annular sealing surface 32 circumference are concentric.

Referring to FIGS. 8A, 8B and 8C, the valve 28 may be injection molded as a housing 28H, having a longitudinally projecting sheath 28P and radially extending valve cup 26. The optional blades 28B may be integrally molded with the sheath 28P or later added. The optional blades 28B may be internal to the sheath 28P, external to the sheath 28P or any combination thereof. The moving assembly 28M and valve stem 28S may be later added as separate components.

Referring to FIGS. 9-10, alternatively or additionally, the sheath 28P may be cantilevered from the top of the outer container 22. In such an embodiment, the sheath 28P may be joined to the outer container 22 after blow molding. Alternatively, and preferably, the sheath 28P may be integrally molded with the preform 60. This arrangement eliminates an assembly step and the possibly detachment. Either such embodiment, having a circumscription sheath 28P has the benefit of increasing rigidity of the respective component and protecting the valve stem from side impact throughout all 360 degrees.

An optional seal 30 may be used, to improve the pressure boundary below or at the threads 25. The seal 30 may separate the first sealing surface 31 and second sealing surface 32.

Referring to FIGS. 11-12, alternatively the upstanding sheath 28P may comprise at least one, and preferably three or more circumferentially spaced, upstanding struts 28P. The struts 28P may be cantilevered from the valve housing 28H. Each strut 28P longitudinally extends beyond the valve stem 28S. If discretely spaced struts 28P are selected, preferably such struts 28P are equally circumferentially spaced and further equally radially spaced about the longitudinal axis to more uniformly distribute compressive loads.

The struts 28P may be parallel to the longitudinal axis, oriented radially inwardly or radially outwardly as desired. This arrangement provides the benefit that the struts 28P can serve the dual functionalities of protecting the valve stem 28S and serving as optional blades 28B for applying rotational motion, while conserving material over a circumscription sheath 28P.

The sheath 28P may be directly joined to the valve 28 or may be indirectly joined to the valve 28. For example, the sheath 28P may be joined to and upstanding from a product delivery device 55, 56, which, in turn, is joined to the valve 28. All such embodiments are contemplated within the scope of the claimed invention and are considered to incorporate a sheath 28P joined to a valve 28.

Struts 28P and a circumscription sheath 28P which are concentric to the longitudinal axis and of constant geometry are shown. The invention is not so limited. The sheath 28P may be eccentric, of variable thickness, variable height, crenulated, fully or partially circumscribe the valve stem 28S, etc., so long as the valve stem 28S is protected. Likewise, the valve stem 28S may be concentrically located, as shown, or be eccentric to the longitudinal axis, and/or may be parallel to or skewed relative to the longitudinal axis. A single valve stem 28S may be used or plural valve stems 28S may be used.

Either geometry protects the valve stem 28S during storage and assembly. For example, if the aerosol containers 20C are soldier stacked prior to product 42 fill and adding the actuator 29, the sheath 28P protects the valve stem 28S from compressive loads due to the layers stacked above.

The invention comprises various embodiments and combinations, as set forth below in exemplary, non-limiting manner It is to be understood that any of the variations, and combinations listed in each of the embodiments for the outer container 22, aerosol container 20C aerosol dispenser 20 and/or preform 60 may be used for any other such embodiment without limitation.

Each combination and variation described herein for an execution as a preform, valve, outer container, aerosol container or an aerosol dispenser is suitable for and can be deployed in any other execution.

-   -   A. An aerosol container 20C having a longitudinal axis and         comprising:

an outer container 22 comprising a closed end bottom and an open neck 24 longitudinally opposed thereto, said open neck 24 having a valve 28 joined to said outer container 22 in fluid tight relationship,

said valve 28 having a valve stem 28S projecting upwardly to a valve stem 28S distal end,

a product delivery device 55, 56 joined to at least one of said valve 28 and said outer container 22 in fluid tight relationship, and

a sheath 28P extending upwardly to a sheath distal end, said distal end of said sheath 28P being at or above said valve stem 28 distal end.

-   -   B. An aerosol container 20C according to paragraph A wherein         said sheath circumscribes said valve stem 28S.     -   C. An aerosol container 20C according to paragraphs A and B         wherein said sheath 28P projects upwardly from a sheath proximal         end joined to said valve 28.     -   D. An aerosol container 20C according to paragraphs A, B and C         wherein said sheath 28P projects upwardly from a sheath proximal         end joined to said valve 28, said sheath 28P being integral with         said valve 28.     -   E. An aerosol container 20C according to paragraphs A and B         wherein said sheath 28P projects upwardly from a sheath proximal         end joined to said outer container 22.     -   F. An aerosol container 20C according to paragraphs A, B and E         wherein said sheath 28P projects upwardly from a sheath proximal         end joined to said outer container 22 said sheath 28P being         integral with said outer container 22, and further comprising         propellant 40 within said outer container 22.     -   G. A normally closed valve 28 for an aerosol container 20C, said         normally closed valve 28 having a longitudinal axis and         comprising:         -   a housing 28H, a moving assembly 28M disposed in said             housing 28H, a valve stem 28S disposed in said moving             assembly 28M, said valve stem 28S projecting longitudinally             to a valve stem 28S distal end, a sheath 28P disposed             radially outboard of said valve stem 28S and projecting             longitudinally to at least one sheath distal end, said             sheath distal end projecting longitudinally further than             said valve stem 28S distal end.     -   H. A valve 28 according to paragraph G wherein said sheath 28P         comprises at least one discrete, upstanding strut 28P, spaced         radially from said valve stem 28S.     -   I. A valve 28 according to paragraphs G and H wherein said         sheath 28P comprises at least three discrete, equally         circumferentially spaced upstanding struts 28P, each said strut         28P being parallel said longitudinal axis.     -   J. A valve 28 according to paragraph G wherein said sheath 28P         circumscribes said valve stem 28S and extends longitudinally         thereabove.     -   K. A valve 28 according to paragraphs G and J wherein said         sheath 28P circumscribes said valve stem 28S, said sheath 28P         having an inner periphery and an outer periphery opposed         thereto, said sheath 28P further comprising a plurality of         longitudinally oriented blades 28B joined to one of said inner         periphery and said outer periphery and extending radially         therefrom.     -   L. A valve 28 according to paragraphs G, J and K wherein said         sheath 28P circumscribes said valve stem 28S, said sheath 28P         having an inner periphery and an outer periphery opposed         thereto, said sheath 28P further comprising a plurality of         longitudinally oriented blades 28B integral with and extending         radially inwardly from said inner periphery.     -   M. A valve 28 according to paragraphs G, J, K and L wherein said         sheath 28P circumscribes said valve stem 28S, said sheath 28P         having an inner periphery and an outer periphery opposed         thereto, said sheath 28P further comprising a plurality of         longitudinally oriented blades 28B joined to one of said inner         periphery and said outer periphery and extending radially         therefrom, wherein said sheath 28P comprises PET, said housing         28H comprises PET and said moving assembly 28M comprises TPE.     -   N. A valve 28 according to paragraph G wherein said sheath 28P         comprises at least four discrete, equally circumferentially         spaced upstanding struts 28P, each said strut 28P being parallel         said longitudinal axis, each strut 28P having a face so that         said strut 28P can act as a blade responsive to axial torque         applied thereto.     -   O. An outer container 22 for an aerosol container 20C usable as         an aerosol dispenser 20, said outer container 22 having a         longitudinal axis and comprising:

a closed end bottom and an open neck 24 longitudinally opposed thereto, said neck 24 having a neck diameter, a sheath 28P projecting longitudinally upward from said neck 24, said sheath 28P having a sheath diameter greater than said neck diameter.

-   -   P. An outer container 22 according to paragraph O further         comprising:

a valve cup 26 joined to said outer container 22 in fluid tight relationship,

a valve 28 disposed within said valve cup 26, said valve 28 having an upwardly projecting valve stem 28S, said valve stem 28S being disposed longitudinally at or below said sheath 28P,

a product delivery device 55, 56 joined to at least one of said valve 28 and said outer container 22 in fluid tight relationship, and

propellant 40 disposed within said outer container 22.

-   -   Q. An outer container 22 according to paragraphs O and P further         comprising:

a valve cup 26 joined to said outer container 22 in fluid tight relationship,

a valve 28 disposed within said valve cup 26, said valve 28 having an upwardly projecting valve stem 28S, said valve stem 28S being disposed longitudinally at or below said sheath 28P,

a product delivery device 55, 56 joined to said outer container 22 or said valve 28 in fluid tight relationship, and

propellant 40 disposed within said outer container 22,

wherein said product delivery device 55, 56 comprises a bag 55 joined to at least one of said valve 28 and said outer container 22 in fluid tight relationship.

-   -   R. An outer container 22 according to paragraphs O, P and Q         further comprising:

a valve cup 26 joined to said outer container 22 in fluid tight relationship,

a valve 28 disposed within said valve cup 26, said valve 28 having an upwardly projecting valve stem 28S, said valve stem 28S being disposed longitudinally at or below said sheath 28P,

a product delivery device 55, 56 joined to said outer container 22 or said valve 28 in fluid tight relationship, and

propellant 40 disposed within said outer container 22,

wherein said product delivery device 55, 56 comprises one of a bag 55 and dip tube 56 joined to at least one of said valve 28 and said outer container 22 in fluid tight relationship,

wherein said sheath 28P circumscribes said valve stem 28S.

-   -   S. An outer container 22 according to paragraphs O, P, Q and R         further comprising:

a valve cup 26 joined to said outer container 22 in fluid tight relationship,

a valve 28 disposed within said valve cup 26, said valve 28 having an upwardly projecting valve stem 28S, said valve stem 28S being disposed longitudinally at or below said sheath 28P,

a product delivery device 55, 56 joined to said valve 28 in fluid tight relationship, and

propellant 40 disposed within said outer container 22,

wherein said product delivery device 55, 56 comprises at least one of a bag 55 and dip tube 56 joined to at least one of said valve 28 and said outer container 22 in fluid tight relationship,

wherein said sheath 28P circumscribes said valve stem 28S, said sheath 28P projecting upwardly from a proximal end in a direction substantially parallel to said longitudinal axis and having a constant wall thickness.

-   -   T. An outer container 22 according to paragraphs O, P and Q         further comprising:

a valve cup 26 joined to said outer container 22 in fluid tight relationship,

a valve 28 disposed within said valve cup 26, said valve having an upwardly projecting valve stem 28S, said valve stem 28S being disposed longitudinally at or below said sheath 28P,

a product delivery device 55, 56 joined to said valve 28 in fluid tight relationship, and

propellant 40 disposed within said outer container 22,

wherein said product delivery device 55, 56 comprises at least one of a bag 55 and dip tube 56 joined to at least one of said valve 28 and said outer container 22 in fluid tight relationship,

wherein said sheath 28P comprises at least three circumferentially spaced upstanding struts 28P, said struts 28P being disposed radially outward of said valve stem 28S and being integral with said outer container 22.

The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as “40 mm” is intended to mean “about 40 mm” and a pressure disclosed as “about 1100 kPa” is intended to include 1103.2 kPa.

Every document cited herein, including any cross referenced or related patent or application, is hereby incorporated herein by reference in its entirety unless expressly excluded or otherwise limited. The citation of any document is not an admission that it is prior art with respect to any invention disclosed or claimed herein or that it alone, or in any combination with any other reference or references, teaches, suggests or discloses any such invention. Further, to the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern. All limits shown herein as defining a range may be used with any other limit defining a range. That is the upper limit of one range may be used with the lower limit of another range, and vice versa.

While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention. 

1. An aerosol container having a longitudinal axis and comprising: a polymeric outer container comprising a closed end bottom and an open neck longitudinally opposed thereto, said open neck having a polymeric valve joined to said outer container in fluid tight relationship, said polymeric valve having a polymeric valve stem projecting upwardly to a valve stem distal end, a product delivery device joined to at least one of said valve and said outer container in fluid tight relationship, and a sheath extending upwardly to a sheath distal end, said distal end of said sheath being at or above said valve stem distal end.
 2. An aerosol container according to claim 1 wherein said sheath circumscribes said polymeric valve stem.
 3. An aerosol container according to claim 1 wherein said sheath projects upwardly from a sheath proximal end joined to said polymeric valve.
 4. An aerosol container according to claim 1 wherein said sheath projects upwardly from a sheath proximal end joined to said polymeric valve, said sheath being integral with said polymeric valve.
 5. An aerosol container according to claim 1 wherein said sheath projects upwardly from a sheath proximal end joined to said polymeric outer container.
 6. An aerosol container according to claim 1 wherein said sheath projects upwardly from a sheath proximal end joined to said polymeric outer container said sheath being integral with said polymeric outer container, and further comprising propellant within said polymeric outer container.
 7. (canceled)
 8. An aerosol container according to claim 1, wherein said sheath comprises at least one discrete, upstanding strut, spaced radially from said polymeric valve stem.
 9. An aerosol container according to claim 1, wherein said sheath comprises at least three discrete, equally circumferentially spaced upstanding struts, each said strut being parallel said longitudinal axis.
 10. (canceled)
 11. An aerosol container according to claim 1, wherein said sheath circumscribes said polymeric valve stem, said sheath having an inner periphery and an outer periphery opposed thereto, said sheath further comprising a plurality of longitudinally oriented blades joined to one of said inner periphery and said outer periphery and extending radially therefrom.
 12. An aerosol container according to claim 1, wherein said sheath circumscribes said polymeric valve stem, said sheath having an inner periphery and an outer periphery opposed thereto, said sheath further comprising a plurality of longitudinally oriented blades integral with and extending radially inwardly from said inner periphery.
 13. An aerosol container according to claim 1, wherein said sheath circumscribes said polymeric valve stem, said sheath having an inner periphery and an outer periphery opposed thereto, said sheath further comprising a plurality of longitudinally oriented blades joined to one of said inner periphery and said outer periphery and extending radially therefrom, wherein said sheath comprises PET.
 14. An aerosol container according to claim 1, wherein said sheath comprises at least four discrete, equally circumferentially spaced upstanding struts, each said strut being parallel said longitudinal axis, each strut having a face so that said strut can act as a blade responsive to axial torque applied thereto.
 15. A polymeric outer container for an aerosol container usable as an aerosol dispenser, said polymeric outer container having a longitudinal axis and comprising: a closed end bottom and an open neck longitudinally opposed thereto, said neck having a neck diameter, a sheath projecting longitudinally upward from said neck, said sheath having a sheath diameter greater than said neck diameter; a polymeric valve cup joined to said outer container in fluid tight relationship, a polymeric valve disposed within said polymeric valve cup, said polymeric valve having an upwardly projecting valve stem, said valve stem being disposed longitudinally at or below said sheath, a product delivery device joined to at least one of said polymeric valve and said outer container in fluid tight relationship, and propellant disposed within said outer container. 16-20. (canceled) 